CONTOH

PRODUK
TAHAPAN INJECTION MOULDING
1.  PELEBURAN RESIN
2.  INJEKSI RESIN YANG TELAH LEBUR KE DALAM
CETAKAN TERTUTUP
3.  PENDINGINAN RESIN DI DALAM CETAKAN
TERTUTUP
4.  PEMBUKAAN CETAKAN DAN PENGELUARAN
PLASTIK HASIL PENCETAKAN
CONVENTIONAL INJECTION MOULDING
RECIPROCATING SCREW INJECTION
KELEBIHAN INJECTION MOULDING
—  PRODUKTIVITAS TINGGI
—  DAPAT UNTUK MENGHASILKAN BENTUK BESAR
—  BIAYA OPERATOR RENDAH PER UNIT MESIN
—  PRODUK TIDAK MEMERLUKAN ‘FINISHING’
—  DAPAT MENGHASILKAN PERMUKAAN, WARNA
DAN ‘FINISHING’ YANG BERBEDA
—  PENGGUNAAN PELBAGAI PLASTIK DAPAT
DILAKUKAN TANPA PERLU MENUKAR MESIN
ATAU CETAKAN
—  EKONOMIS
KEKURANGAN INJECTION MOULDING

—  INDUSTRI PLASTIK MEMPUNYAI KEUNTUNGAN

YANG RENDAH (LOW PROFIT MARGIN)
—  OPERASI TIGA SHIFT PERLU UNTUK BERSAING
—  BIAYA CETAKAN SANGAT TINGGI
—  MESIN DAN PERALATANNYA MAHAL
—  KONTROL PROSES MUNGKIN TIDAK BEGITU BAIK
—  PERALATAN TIDAK KONSISTEN PADA SAAT
BEROPERASI
—  KUALITAS AGAK SUKAR DITENTUKAN
PRINSIP PROSES
♦ LEBURAN ATAU ‘PLASTICISED’ PLASTIK DIINJEKSI ATAU
DITEKAN KE DALAM CETAKAN LALU DIDIAMKAN DAN
D I K E L U A R K A N D A L A M K E A D A A N P E J A L D A N
MENYERUPAI RONGGA CETAKAN YANG DIGUNAKAN
—  CETAKAN DAPAT TERDIRI DARI SATU RONGGA ATAU
BANYAK (MULTI CAVITY) YANG BERBENTUK SAMA ATAU
BERLAINAN, YANG DISAMBUNGKAN DENGAN ‘RUNNERS’
YANG MENGARAHKAN LEBURAN KE SETIAP RONGGA
♦PROSES INI MERUPAKAN SALAH SATU PROSES YANG
PALING EKONOMIK UNTUK PRODUK SECARA BESAR-
BESARAN

SPRUE, “RUNNER”, GATE DAN CAVITY
URUTAN PERGERAKAN MEKANIS UMUM
PADA SAAT PROSES:
—  PENGAPIT CETAKAN DITUTUP
—  RAM INJEKSI BERGERAK KE DEPAN UNTUK
MENGINJEKSI LEBURAN
—  SKRU MENGEPAM KE BELAKANG APABILA
LEBURAN DINGIN DALAM CETAKAN
—  SKRU BERHENTI BERPUTAR DAN PENGAPIT
DIBUKA
—  PLASTIK TERCETAK DITOLAK KELUAR DARI
CETAKAN
UNTUK MENDAPATKAN HASIL YANG OPTIMUM
—  TEMPERATUR PELEBURAN
—  TEKANAN PENYUNTIKAN (INJECTION PRESSURE)
—  KECEPATAN PENGISIAN CETAKAN (INJECTION
SPEED)
TEMPERATUR PELEBURAN
—  PLASTIK BERBEDA DARI SEGI VISKOSITAS
(MAMPU ALIR – EASE OF FLOW) DAN MASALAH
INI MENJADI LEBIH RUMIT DENGAN ADANYA
GRADE YANG BERVARIASI

—  SIFAT MAMPU ALIR PLASTIK ADALAH NON-
NEWTONIAN (HUBUNGAN TIDAK LINEAR
ANTARA TEKANAN DAN PENGALIRAN)
CONTOH VISKOSITAS PLASTIK PADA
TEMPERATUR YANG BERBEDA

BAHAN VISKOSITAS PADA 1,000 s-1

(NYLON)
240˚C 260˚C 280˚C 300˚C
1 98 78 63 50
2 149 115 89 69
3 394 319 259 210
CONTOH VISKOSITAS PLASTIK PADA
TEGANGAN GESER BERBEDA
BAHAN VISKOSITAS PADA SUHU 280˚C

100s-1 1000s-1 10000s-1 100,000

s-1
1 197 63 20 6

2 323 89 25 7

3 1220 259 55 12
—  DALAM KASUS UMUM, PLASTIK ADALAH BERSIFAT
PSEUDOPLASTIK YAITU MENJADI KURANG VISKOS
BILA DIGERAKKAN DENGAN CEPAT
—  VISKOSITAS BAHAN BERKURANG BILA TEGANGAN
DITINGKATKAN (INJECTION MOULDING LEBIH
MUDAH)
—  MENINGKATKAN TEMPERATUR LEBURAN AKAN
M E N U R U N K A N T E K A N A N I N J E K S I Y A N G
DIPERLUKAN PADA KADAR PENGALIRAN TERTENTU
SUHU PENGINJEKSIAN BEBERAPA JENIS PLASTIK
TEKANAN INJEKSI

•  SEMASA PENGISIAN CETAKAN, TEKANAN

INJEKSI TINGGI PERLU UNTUK MENJAGA
KECEPATAN PENGISIAN CETAKAN YG
DIPERLUKAN
•  BILA CETAKAN TELAH PENUH, TEKANAN
TINGGI TIDAK LAGI DIPERLUKAN
•  DAPAT MENGGUNAKAN 2 PERINGKAT
TEKANAN
KECEPATAN INJEKSI
—  BILA MENCETAK PRODUK TIPIS, KECEPATAN
TINGGI DIPERLUKAN UNTUK MEMENUHI
CETAKAN SEBELUM PEMBEKUAN BAHAN
—  UNTUK MENDAPATKAN PERMUKAAN YANG BAIK
BAGI PRODUK TEBAL, DIGUNAKAN INJEKSI
PERLAHAN
—  BAGI KEBANYAKAN MESIN, MASA UNTUK
MENGISI CETAKAN SELESAI DALAM SUATU SAAT

Cetak Injeksi Bahan Termoplastik :
Bahan cetak dimasukkan
ke ruang pengumpan;
Dengan gaya gravitasi
bahan masuk ke ruang
pemanas, setelah
melalui alat pengukur;
Akibat pemanasan (120-
260OC), bahan
mengalami plastitisisasi dan kemudian diinjeksikan ke dalam
cetakan tertutup dengan tekanan
cukup besar (sekitar 200 MPa);

Produk cetak mengeras di bawah pengaruh pendinginan air;

Penekan ditarik dan produk dikeluarkan.
Cetak Injeksi Bahan Termoset :
Bahan cetak dimasukkan
ke ruang pengumpan ;

Dengan gaya gravitasi

bahan masuk ke dalam
tabung dan didorong ke
depan oleh ulir yang
berputar dan sekaligus
dipanaskan;

✔ Akibat pemanasan, bahan

di depan ulir mengalami plastisisasi dan masih tertahan oleh

plunyer sampai jumlah bahan tertentu;
Cetak Injeksi Bahan Termoset :
Plunyer turun dan ulir me-
maksa bahan memasuki
ruang transfer;
Bahan ditekan memasuki
ruang cetakan;
Bahan mengalami penge-
rasan, produk jadi.
Cetak Rotasi : Bahan termoplastik
dimasukkan ke dalam
cetakan;
Cetakan diputar dan
dipanaskan sehingga
(a) (b) partikel meleleh pada
Figure 6.8
Schematic of rota jonal molding showing two mold bagian dalam cetakan;
mouting systems
Akibat gaya sentrifugal partikel cair melekat pada dinding
cetakan, membentuk lapisan;
Cetakan dibuka dan produk dikeluarkan;
Mesin disiapkan untuk produk berikutnya.
Cetak Tiup :
Bahan plastik
(parison) dimasuk-
kan melalui hopper,
kemudian dieks-
trusi secara cepat
hingga ke luar dari
Figure 6.10
Typical blow-molding machine. ruang mesin;

Pada waktu cetakan ditutup parison terpotong, dan akibat

tekanan udara bahan tertekan ke permukaan cetakan;

Setelah produk cukup dingin, cetakan dibuka dan produk

dikeluarkan.
Bahan Cetakan : F baja yang diberi perlakuan panas.
Pembuatan Cetakan : F dengan pemesinan presisi.
Faktor penting yang perlu diperhatikan dalam
pembuatan cetakan :
F Diperlukan tirus dan sudut-sudut tertentu untuk memu-
dahkan mengeluarkan benda dari cetakan;
F  Diperlukan pen ejektor untuk mengeluarkan benda dari
cetakan, dan harus diletakkan ditempat yang tidak meng-
ganggu;
F  Harus diperhitungkan penyusutan bahan yang biasanya
berkisar antara 0,003 hingga 0,009 mm per milimeter (0,3 –
0,9 %).
Desain Sistem Saluran
Injection Molding
 High-performance Mold

A high-performance mold harus memilliki karakteristik

yang baik dalam hal ：
High-performance dalam sistem pengisian
High-performance sistem packing
High-performance sistem pendinginan
Contoh Mold Casting System
 Gating System and their effects

Sprue Runner gate

Main Branch
runner runner

Branch runner
runner
Cavity

runner system has a direct impact on the appearance, physical properties and of
dimensional accuracy and cycle time of molded product
 Prinsip Desain Sistem Saluran

1.  guarantee the quality of parts

(to avoid the common problem of filling)

Minimize hesitation

hesitation is easy to make overpacking on

some part of the workpiece, and underpacking
for other part
 Prinsip Desain Sistem Saluran
1.  guarantee the quality of parts

Gate Placed on the Thickest part of Product

n  From the thickest pouring provide better filling and packing effects
n  If there are underpacking, the thinner areas will solidify faster than thick
regions
n  Avoid gate on the region with sudden change of wall thickness, prevent
hysteresis or short shot

Sink
缩坑mark

未凝固处
Un-cure
Under
保压不足 packing
浇口
gate

不推荐
Sink
缩坑mark
 Prinsip Desain Sistem Saluran
1.  guarantee the quality of parts

Meltline
Try to avoid meltline

Meltline exists primarily affect the

appearance, making the poor surface of
product; poor Weld strength
 Melt Lines

•  Melt from different directions, the front part of the molten resin is cooled in the
junction can not fully integrated. Under normal circumstances, affect the
appearance, impact on the coating, electroplating. Severe impact on the
product strength (especially fiber reinforced resin)
 Prinsip Desain Sistem Saluran
1.  guarantee the quality of parts

sink
avoid overpacking
and underpacking

overpacking rib

poor gating system design or improper operating underpacking

conditions, make the melt pressure in the cavity takes too
long or too high
overpacking will make the product density, to increase the
internal stress, or even flash
Prinsip Desain Sistem Saluran
1.  guarantee the quality of parts

Minimize the flow disorderly

flow disorderly make poor workpiece strength and surface flow

Simple Complex
 Prinsip Desain Sistem Saluran

2. Minimize the cross-section and length of gating system

Minimize heat loss and pressure loss of the plastic melt

Reduce the amount of plastic and mold size

3. synchronize filling

For multi-cavity mold, make different cavity melt arrive at the same time, and
equal to the pressure at the entrance of each cavity
 Filling in the Central

n  Gate placed in the central of the product are available for same flow
length
n  Long flow length will affect the required injection pressure
n  Central pouring makes all directions holding pressure evenly to avoid
uneven volume shrinkage
 Symmetry of Gates
n  Symmetry gates can avoid product warpage
n  Asymmetric flow will lead to filling first in certain areas, even before solidification
may cause uneven product of the volume shrinkage, which will cause warpage
 Runner Design and Manufacture
1. Runner section shape

Circular cross-section

Advantage：The shape of flow channel with high efficiency, up to 0.25D

Shortcoming：Increase production costs, flow channel interleaving will
affect flow efficiency
 Runner Design and Manufacture
1. Runner section shape

Rectangular cross section

The efficiency of flow channel is nearly

equal to Circular section, 27% area more
than that of Circular, increase injection
waste and demolding force
 Runner Design and Manufacture
1. Runner section shape

U shaped

Also known as the modified trapezoidal flow channel, combined with the round and
trapezoid advantages, 14% area more than that of circular
 Runner Design and Manufacture
2. Runner design points

Volume and wall thickness of the products, the Runner section thickness is greater
than the wall thickness of the products
The fluidity of the molding resin, the resin with glass fiber and less flowability, larger
flow channel cross-section needed
Change the direction of the flow channel around the corner, should be properly set
cold slug
make the plastic parts and flow channel in the geometric center of the clamping
force, in the center of projected area
 Runner Design and Manufacture
3. Runner size design

Flow channel diameter is too large: not only a waste of materials, and the cooling
time increased, the molding cycle also grows, resulting in waste costs.
Flow channel diameter is too small: the flow resistance of the material, could
easily lead to the filling or injection pressure must be increased in order to fill.
Runner diameter should be suitable for the weight of the product or the projected
area

Diameter of the Diameter of the

Projected
flow Product weight(g) flow
area(cm2)
channel(mm) channel(mm)
4 95 4 Less than 10
6 6 200
375
8 8 500
10 More than 375
10 1200
12 Large-scale 12 Large-scale
 Runner Design and Manufacture
4. Runner Road layout

v  principle of flow channel array

Ø same distance for molten plastic from sprue to different gate
Ø  The cavity center of pressure coincide with the center of injection
molding machine

v The layout of the flow channel

Natural balance Artificial balance

Unbalanced Natural balance Artificial balance

 Artificially Balanced Runner System
filling order for different cavity is extremely complex, not only with the
section size and length of the Runner, and the plastic melt temperature,
pressure, viscosity, mold temperature and viscosity on pressure drop
and temperaturelowering the degree of sensitivity. Gate size of the
balance of each cavity can be fixed after the test mold or mold flow
analysis
 Runner Design and Manufacture

4. Runner
Road
balance of Runner arrangement
layout

unbalance of Runner arrangement

Design and Manufacture of Gate
 Design and Manufacture of Gate
1. role of gate
gate：Gate: a bridge connected Runner and cavity, is the weakest and
most critical part in the system

• Adjust flow speed

• Adjust feed time
• Prevent back flow

Gate dimension often determined by experience, take

low value first, then revised by trying. generally, the
gate area size is about 3-9% of that of runner, with
short length about 1-1.5mm, often using rectangle or
round section
 Design and Manufacture of Gate
1.role of gate

the suitability of Gate location, number, shape, size has a direct impact on
product appearance, dimensional accuracy, physical properties and molding
efficiency
too small Gate : easily lead to the
filling (short shots), sink marks, Dimension
reduced
weld defects in appearance, and
too small gate
shrinkage increases

too large Gate: excess residual

stress around gate, resulting in swell
deformation or rupture, and the
gate removal difficult too big Gate
 Design and Manufacture of Gate

2. type and characteristics of gate

Direct gate(sprue gate)

Direct gate is widely used in single-cavity mold

Disadvantages: difficult removal of gate, leave
marks on surface of molding
 Design and Manufacture of Gate

2. type and characteristics of gate

side gate
Generally opened in the parting surface,
suitable for multi-cavity mold, convenient
gate removal; but the pressure loss, shell-
shaped venting inconvenience, easy to
produce the weld.

typical size : thickness of 0.4 to 6.4mm,

width from 1.6 to 12.7mm.
 Design and Manufacture of Gate
2. type and characteristics of gate
film gate

Similar to ring gate, with straight edge of the plastic parts

Applies to flat and large area, warping reducing
Typical thickness: 0.25 to 0.63mm, with short length, approximately 0.63mm
 Design and Manufacture of Gate
Gate design principles

⑵Symmetric gate can prevent warping

Set up multiple gates to reduce the deformation

⑶gate location good for melt flow and feeding

Not recommended Recommend

Gate Location Options
Gate Location Options
 Gate Location Options

Location of Reasonable
the gate location of the
gate
Gate location example